Composite ultrasonic material applicators with embedded shaping gas micro-applicators and methods of use thereof

Abstract

A method of controlling application of at least one material onto a substrate includes configuring a material applicator having an array plate with an applicator array. The applicator array has a plurality of micro-applicators with a first subset of micro-applicators and a second subset of micro-applicators. Each of the plurality of micro-applicators has a plurality of apertures through which fluid is ejected. The first subset of micro-applicators and the second subset of micro-applicators are individually addressable, and a liquid flows through the first subset of micro-applicators and a shaping gas, e.g., air, flows through the second subset of micro-applicators. The flow of shaping gas shapes the flow of the liquid from the first subset of micro-applicators to the substrate.

What is claimed is: 
     
       1. A material applicator for controlling application of at least one material to a substrate, the material applicator comprising:
 an array plate comprising a plurality of micro-applicators, each micro-applicator including:
 a micro-applicator plate defining a plurality of apertures extending through the micro-applicator plate; 
 a frame cooperating with the micro-applicator plate to define a reservoir; 
 a material inlet in fluid communication with the reservoir; and 
 an actuator configured to vibrate to eject a liquid from the reservoir through the plurality of apertures, 
 
 wherein the plurality of micro-applicators includes a first subset of the micro-applicators and a second subset of the micro-applicators, 
 wherein the material applicator is configured to be operated in a first mode wherein the material inlets of the micro-applicators of the first subset are connected to a first material source and the material inlets of the micro-applicators of the second subset are connected to a second material source, 
 wherein in the first mode, the first material source is configured to supply liquid to the material inlets of the first subset of micro-applicators and the second material source is configured to supply pressurized gas to the material inlets of the second subset of micro-applicators. 
 
     
     
       2. The material applicator according to  claim 1  further comprising a controller configured selectively operate the actuators of the micro-applicators, wherein, when operating in the first mode, the controller operates the actuators of the first subset to eject liquid from the first subset while simultaneously spraying pressurized gas through the plurality of apertures of the second subset. 
     
     
       3. The material applicator according to  claim 2 , wherein the controller is configured to switch the material applicator from the first mode to a second mode in which at least one micro-applicator of the first subset sprays pressurized gas while liquid is simultaneously sprayed from at least one other micro-applicator of the first subset. 
     
     
       4. The material applicator according to  claim 3 , wherein the liquid sprayed from the at least one other micro-applicator of the first subset in the second mode is a different liquid than the liquid ejected from the first subset in the first mode. 
     
     
       5. The material applicator according to  claim 2 , wherein the controller is configured to switch the material applicator from the first mode to a second mode in which at least one micro-applicator of the first subset sprays pressurized gas while liquid is simultaneously sprayed from at least one micro-applicator of the second subset. 
     
     
       6. The material applicator according to  claim 5 , wherein the liquid sprayed from the at least one other micro-applicator of the second subset in the second mode is a different liquid than the liquid ejected from the first subset in the first mode. 
     
     
       7. The material applicator according to  claim 2 , wherein the controller is configured to switch the material applicator from the first mode to a second mode in which at least one micro-applicator of the first subset sprays pressurized gas while liquid is simultaneously sprayed from at least one other micro-applicator of the first subset and the at least one micro-applicator of the second subset. 
     
     
       8. The material applicator according to  claim 2 , wherein the controller is configured to switch the material applicator from the first mode to a second mode in which at least one micro-applicator of the second subset sprays liquid. 
     
     
       9. The material applicator according to  claim 8 , wherein the liquid sprayed from the at least one other micro-applicator of the second subset in the second mode is a different liquid than the liquid ejected from the first subset in the first mode. 
     
     
       10. The material applicator according to  claim 2 , wherein the actuators corresponding to micro-applicators spraying pressurized gas are not activated while the pressurized gas is sprayed therefrom. 
     
     
       11. The material applicator according to  claim 1 , wherein each actuator is configured to vibrate a corresponding one of the micro-applicator plates. 
     
     
       12. The material applicator according to  claim 1  further comprising a controller in electrical communication with each actuator, wherein each micro-applicator is individually addressable to be controlled separately by the controller. 
     
     
       13. The material applicator according to  claim 1 , wherein each actuator is an ultrasonic transducer. 
     
     
       14. The material applicator according to  claim 1 , wherein the array plate includes a plurality of planes and one or more micro-applicators of the plurality of micro-applicators is located on a first plane of the plurality of planes and one or more different micro-applicator of the plurality of micro-applicators is located on a second plane of the plurality of planes. 
     
     
       15. The material applicator according to  claim 14 , wherein the first plane is parallel to but offset from the second plane. 
     
     
       16. The material applicator according to  claim 14 , wherein the first plane is not parallel to the second plane. 
     
     
       17. The material applicator according to  claim 1 , wherein the array plate is concave or convex. 
     
     
       18. A material applicator for controlling application of at least one material on a substrate comprising:
 an array of micro-applicators comprising a first subset of micro-applicators and a second subset of micro-applicators different than the first subset of micro-applicators, wherein each of the micro-applicators in the array of micro-applicators comprises a micro-applicator plate, a plurality of apertures extending through the micro-applicator plate, a reservoir in fluid communication with the plurality of apertures; 
 a plurality of first transducers, each first transducer being in mechanical communication with a corresponding one of the micro-applicator plates in the first subset of micro-applicators; and 
 a plurality of second transducers, each second transducer being in mechanical communication with a corresponding one of the micro-applicator plates in the second subset of micro-applicators, 
 wherein a liquid supply is in fluid communication with the plurality of apertures of each of the micro-applicators in the first subset of micro-applicators and a pressurized gas supply is in fluid communication with the plurality of apertures of each of the micro-applicators in the second subset of micro-applicators. 
 
     
     
       19. The material applicator according to  claim 18 , wherein the first subset of micro-applicators and the second subset of micro-applicators are individually addressable.